AIR COMPRESSOR SERIES ENGINEERING EXCELLENCE S STELLAR PERFORMANCE P-700 RELIABLE 100% OIL-FREE ENGINEERED AIR A World Leader for Centrifugal Compressors
It s simple: The Polaris Air Compressor Series delivers 100% oil-free engineered air reliably and efficiently. FS-Elliott s Polaris Air Compressor Series incorporates the latest technology to ensure high efficiency, economy and reliability. The Plant Air Package (PAP) compressor was introduced to the marketplace nearly 50 years ago. Since its introduction, thousands of units have been installed and operate worldwide. Electronics Automotive Steel Making Glass Making and P.E.T. Food and Beverage Processing Mining Snow Making Air Separation Utilities Chemical Textile And Many Other Markets The Polaris Air Compressor Series design features provide benefits ranging from ease of installation, operation and maintenance to highest efficiency. 1. High Base-load and Part-load Efficiency 2. Optimized Operational Efficiency Throughout the Entire Year 3. Minimum Number of Moving Parts 4. Robust and Reliable Industrial Design 5. Superior Package Design 6. Simple, Low-cost Installation 7. Elimination of Air Line Oil Contamination 8. Ease of Operation 9. Ease of Maintenance 10. Professional Service 9 2 1 8 7 5 4 3 6 Typical Operation 1 2 Ambient air enters the first stage of the compressor through the inlet control device. The air is accelerated by the first impeller. A radial diffuser converts the air s velocity into pressure before the air enters an efficient scroll casing. 3 Air enters the first stage high efficiency intercooler and cools as it passes over the water-filled tubes with external fins in the bundle. The straight tubes are easily cleaned to maintain optimum performance. 4 The lower velocity cooled air exits the tube bundle and makes two 90 degree turns. This turning and upward flow path separates the condensed moisture from the cooled air and makes it unnecessary to use demister pads, which are a high maintenance item. The air travels through the large corrosion resistant epoxy coated plenum. Condensate is continuously drained through a drain valve located in the bottom of the intercooler s enclosure. 5 The air exits the intercooler and flows into the inlet duct for the second stage. In the second stage the compression process is repeated with an impeller, diffuser, and a scroll casing. 6 The air discharges from the compressor volute and enters the second stage intercooler. The intercooling process is identical to that in the first stage. 7 8 9 Air from the second intercooler proceeds through the inlet flow section for the third stage impeller. The air is compressed through the third aerodynamic stage and is discharged into the aftercooler. The cooled air exits from the aftercooler into the air system. 2
Polaris Compressors Are Leading The Way Uncompromising Design and Innovative Features The Polaris components are a shining example of reliability and efficiency. Horizontally Split Flex-Pad Journal Bearing and Tapered Land Thrust Bearing Horizontally Split Sleeve Journal Bearing and Flat Land Thrust Bearing Helical Bull Gear (Typical 4 Places) Rotor Assembly Pinion and Single Impeller Rotor Assembly Pinion and Dual Impellers The compressor cut-away view depicts the typical Polaris Air Compressor Series internals. The compressor driver is connected to the main drive shaft end of the bull gear through a flexible coupling. The single helical bull gear is supported by two horizontally-split sleeve journal bearings, while the thrust is absorbed in either direction by flat-land thrust bearings. The bull gear drives two pinions with mounted impellers. The pinion shafts are designed to operate at the optimized rotational speed for the best efficiency. Shaft Seal (Typical 3 Places) Innovative features make the Polaris Air Compressor Series a super-star performer. Impellers The impellers of the Polaris Air Compressor Series are stainless steel. The precipitation hardened, stainless steel material resists the corrosive and erosive action of atmospheric contaminants and water vapor that may pass through the inlet air filter. The state-of-the-art backward-leaning impeller designs provide superior overall aerodynamic performance characteristics. 3
Pressure Lubrication System The lubrication system has proven its reliability through many years of successful operating experience. The system is self-contained within the compressor package and is designed for easy access and maintenance. This system provides for all of the package s needs, which include continuous oil flow to all bearings and gears, as well as the driver when required. The oil lubrication system is designed with ease of inspection and maintenance as one of its primary goals. Therefore, all of the oil connections are positioned in the lower half of the gear case for quick and simple access to the bearings, gears and pinions. Bleed Line Main Oil Pump Polaris Compressor Filter Oil Mist Eliminator Driver Thermal Valve Cooler Relief Valve Oil Temperature Transmitter Oil Pressure Transmitter Panel Check Valve 2 Check Valve 1 Oil Reservoir Auxiliary Oil Pump Corona Brand Lubricants For the optimum compressor system operation and extended service life, FS-Elliott recommends the use of Corona Brand lubricant. Our Corona Brand lubricant is supplied with all new FS-Elliott Polaris centrifugal compressors. This premium lubricant is designed for use with centrifugal compressors. This lubricant can also be retrofitted into existing installations. The benefits of Corona Brand lubricants include: Extended Lubricant Life Minimizes Harmful Build-up Excellent Wear Protection Superior Resistance to Foaming Longer Equipment Operating Cycles Free Oil Analysis Program FS-Elliott provides a no-charge analysis service to all current clients that utilize our exclusive Corona Brand lubricants. In addition, we offer this same service to those end users that desire to retrofit their existing compression systems with our premium Corona Brand lubricants. Lubricant sampling and testing can and should be a part of every turbomachinery user s preventative maintenance practices. FS-Elliott recommends that in addition to normal daily and monthly inspections that a quarterly testing frequency be included in this regimen. The returned lubricant samples are analyzed and a report is generated highlighting the current physical and chemical characteristics of the lubricant. Other timely and pertinent lubricant observations related to machinery operations are also included in the report along with our recommendations. FS-Elliott provides an easy-to-use lubricant sample kit to assist in implementing this procedure into your maintenance routine. The FS-Elliott lubricant testing kit contains the following items: Lubricant Sample Container and Stick-on Identification Label Self-addressed Mailing Container Lubricant Datasheet FS-Elliott has a variety of lubricants to meet most specific industry requirements. The FS-Elliott Corona TM Brand lubricants are available in three container sizes: 330 gallon tote, 55 gallon drum and 5 gallon pail. 4
REGULUS Putting You in Control Outstanding Performance with Superior Reliability and Quality The heart of FS-Elliott s centrifugal compressor is the REGULUS Control System. This system is designed with the latest technology processor and memory capabilities to provide optimum performance, reliability and convenience. With the REGULUS System and a touch of the screen you can monitor and manage all of your air compressor needs at the unit or from a remote location. The REGULUS R150 and R200 Control Systems include an optional feature 10" Graphical TFT Color Touch Screen HMI display. The REGULUS Control System includes a powerful PLC packaged with a myriad of monitoring and control features. At the touch of the Human Machine Interface (HMI), the operator can command, observe and manage all of the essential air compressor system requirements. Energy Savings Experience the REGULUS Control System s energy savings features and realize the profitability benefits from Day #1. Precise air system pressure control Maximizes turndown capability and energy savings Advanced adaptive controller permits protected operation closer to actual surge resulting in energy savings Innovative adjustable inlet guide vane design maximizes efficiency at off-design operations Suction Throttle and Auto-Dual control modes add operational flexibility and efficiency Multiple compressor unit energy management capability Simplicity Discover the simplicity of the REGULUS Control System together with the outstanding operational benefits it delivers to your facility. All control set points from one interface Numerous language display capabilities Multiple choices of communication protocols with interfacing systems Supervisory capabilities include monitoring the entire air system from one location Data storage and trend viewing are instantaneously available with the touch of the finger The compressor can virtually run unattended at optimum efficiency through various plant air demand conditions Polaris P-700 Typical Configuration Overall configuration varies with selected drive motor. Polaris P-700 Performance Range A B C Power Rating: 1250 to 2500 HP / 932 to 1864 kw Discharge Pressure: 45 to 150 psig / 3.1 to 10.3 bar g Flow Capacity: 6800 to 12000 ICFM / 193 to 340 m 3 /min Polaris Air Compressor Series Frame Overall Dimensions A* B* C Approximate Weight* in. mm in. mm in. mm lb. kg P-700 181 4597 92 2337 87 2210 28800 13063 *The value may vary with motor rating size and type. Note: Performance may vary based on actual site conditions. Consult your authorized FS-Elliott distributor for more information. 5
At our manufacturing facility and headquarters, located in Export, PA, we take nothing for granted. Every Polaris air compressor is carefully crafted under stringent quality standards. By the time a compressor arrives at your site for installation, it has undergone a rigorous execution process covering the product design, manufacture and inspections governed by our ISO 9001:2000 Certified Quality Management System. When you need answers to your questions, or solutions to your problems, you can rely on FS-Elliott s worldwide network of sales representatives and distributors. We can provide total turnkey installation services at your site, designed to assure your FS-Elliott equipment is up and running as quickly as possible. Our worldwide network of local certified technicians provides professional service twenty-four hours per day, seven days per week, three-hundred-sixty-five days per year. This means you receive timely assistance for all of your needs. Maintenance and repairs can be performed at site: Local Service Genuine FS-Elliott Spare Parts Installation and Start-up Maintenance Programs Repairs Rerates and Upgrades Training FS-Elliott Co., LLC 5710 Mellon Road Export, PA 15632-8948 U.S.A Telephone...(724) 387-3200 FAX...(724) 387-3270 E-mail... info@fs-elliott.com Internet...www.fs-elliott.com REPRESENTED BY: ISO 9001 Certified for design and manufacture of centrifugal compressors. FS-Elliott Co., LLC reserves the right to modify the design or construction of the equipment described in this brochure and to furnish it, as altered, without further reference to the illustrations or information contained herein. FS-Elliott Co., LLC 2008 Bulletin FSP56-408